Disc rotor motor

Abstract

A disc rotor motor is demonstrated, having at least one stator that has at least one electrical stator winding and stator teeth, which have a tooth neck composed of a soft magnetic powder composite, and having at least one disc-shaped rotor, which has permanent magnetic poles composed exclusively of ferrite magnets at least for producing torque, with the rotor and stator oriented parallel to each other and spaced apart from each other by an axial gap. In order to find an optimum between costs, weight, and overall size as well as power and torque density, the invention proposes that the stator teeth each end in a tooth end that adjoins their tooth neck and is composed of a soft magnetic powdered composite, which tooth end widens out in its cross-sectional area in comparison to the tooth neck.

The invention claimed is: 
     
       1. A disc rotor motor, comprising:
 at least one stator that has at least one electrical stator winding and a plurality of stator teeth composed of a soft magnetic powder composite, each of the stator teeth having a tooth neck and a tooth end that adjoins a respective tooth neck, wherein each tooth end widens out in its cross-directional area in comparison to the respective tooth neck and a quotient of a largest cross-sectional area of soft magnetic powder composite of the tooth end (A E ) and a smallest cross-sectional area of soft magnetic powder composite of the respective tooth neck (A H ) is greater than 2, such that (A E /A H )>2; and 
 at least, one disc-shaped rotor comprising permanent magnetic poles for, producing torque, wherein the permanent magnetic poles are generated by magnets consisting of ferrite magnets, and the rotor and stator are oriented parallel to each other and spaced apart from each other by an axial gap, wherein a maximum sum of the cross-sectional areas of the tooth necks (A H ) composed of soft magnetic powder composite are less than a sum of cross-sectional areas (A E ) of the permanent magnetic poles composed of ferrite magnets. 
 
     
     
       2. The disc rotor motor according to  claim 1 , wherein the tooth neck and tooth end are composed of the same soft magnetic powdered composite. 
     
     
       3. The disc rotor motor according to  claim 2 , wherein the tooth neck and tooth end, manufactured as one, form art integral component of the stator, which component is attached to a magnetically conductive stator yoke of the stator. 
     
     
       4. The disc rotor motor according to  claim 1 , wherein the tooth end is placed onto the tooth neck and attached to the tooth neck. 
     
     
       5. The disc rotor motor according to  claim 1 , wherein the tooth neck and a one-piece or multi-piece stator yoke of the stator, manufactured as one, form an integral component. 
     
     
       6. The disc rotor motor according to  claim 1 , wherein the stator teeth are arranged concentrically in an edge region of the stator, and/or the ferrite magnets are arranged concentrically in an edge region of the rotor. 
     
     
       7. The disc rotor motor according to  claim 1 , wherein the rotor has a support disc composed of stainless steel, with openings in a region of the ferrite magnets. 
     
     
       8. The disc rotor motor according to  claim 7 , wherein a first ferrite magnet is inserted into each opening of the support disc and is covered on both sides by respective second ferrite magnets that rest against the support disc. 
     
     
       9. The disc rotor motor according to  claim 8 , wherein the openings in the support disc have a stepped opening edge at both ends, into which the second ferrite magnets protrude in an axially aligned fashion. 
     
     
       10. The disc rotor motor according to  claim 7 , wherein the support disc has slots in an edge region. 
     
     
       11. The disc rotor motor according to  claim 10 , wherein the slots are formed between T-shaped partition pieces of the support disc, and the slots adjoin the openings formed by the T-shaped partition pieces of the support disc for the ferrite magnets. 
     
     
       12. The disc rotor motor according to  claim 7 , wherein the support disc has a circumferential groove in its end surface in which a reinforcing element, in the form of a binding band, is at least partially accommodated. 
     
     
       13. The disc rotor motor according to  claim 12 , wherein the reinforcing element has at least one fiber composed of a glass or carbon material. 
     
     
       14. The disc rotor motor according to  claim 7 , wherein a stator s provided on each of two sides of the rotor. 
     
     
       15. The disc rotor motor according to  claim 1 , wherein the rotor has a magnetically conductive support disc to which the ferrite magnets are fastened over their entire surface, with the stator that is provided on one side of the rotor adjoining the side of the support disc with the ferrite magnets via the axial gap. 
     
     
       16. The disc rotor motor according to  claim 1 , wherein the stator has a magnetically conductive stator yoke and a heat conductor, which has an elevated thermal conductivity in comparison to the stator yoke and, via a recess or opening of the stator yoke, rests against a coil of a wound tooth neck. 
     
     
       17. The disc rotor motor according to  claim 16 , wherein the heat conductor is composed of aluminum or an aluminum alloy.